The service life of electric forklift batteries will experience a temporary capacity decline in winter. Improper maintenance will cause a permanent reduction in service life; if maintained in accordance with specifications, only reversible performance fluctuations will occur, which will not affect the total cycle life of the batteries.
I. Core Principles of How Winter Affects Battery Service Life
1. Inhibition of Battery Chemical Reactions by Low Temperatures
The essence of battery charging and discharging is the electrochemical reaction between the internal positive and negative electrodes, and low temperatures directly reduce the reaction rate:
- Lead-acid batteries: Low temperatures increase the viscosity of the electrolyte and slow down the ion migration speed. This not only reduces the available capacity by 30%–50% but also impairs the charge acceptance capability, which is prone to causing plate sulfation (lead sulfate crystals adhere to the plate surface and block pores). This type of damage is irreversible and directly shortens the battery service life.
- Lithium batteries: Low temperatures inhibit the deintercalation and intercalation efficiency of lithium ions, resulting in sudden voltage drop and premature discharge termination. Forcing charging when the temperature is below 0°C may lead to lithium metal deposition, which can pierce the cell separator, cause internal short circuits, and significantly shorten the battery service life.
2. Indirect Impact of Winter Operating Habits
Power consumption accelerates in winter, leading operators to frequently adopt behaviors such as operating the battery in an undercharged state and supplementary charging at short intervals:
- Discharging the battery beyond 70% of its depth of discharge (especially for lead-acid batteries) will accelerate plate softening.
- Multiple small-current charging cycles in low temperatures will keep the battery in a long-term "undercharged" state, exacerbating sulfation.
II. Comparison of Two Outcomes of Service Life Impact
| Maintenance Status | Performance of Service Life Impact | Reversibility |
|---|
| Improper Maintenance | Plate sulfation in lead-acid batteries and lithium deposition in lithium batteries, reducing the battery cycle life by 20%–40% | Irreversible |
| Standard Maintenance | Only capacity decline in winter; performance recovers when temperature rises, with no impact on total cycle life | Fully Reversible |
III. Key Measures to Avoid Service Life Reduction
- 1.Strictly control the temperature of charging and discharging environment: Maintain the charging room temperature at 10°C–25°C; preheat the battery for 2–4 hours before charging; suspend operations when the temperature is below -10°C.
- 2.Limit the depth of discharge: Do not exceed 70% of the rated capacity in a single discharge cycle; stop the machine and charge immediately when the remaining power is below 30%.
- 3.Standardize the charging process: Adopt stage charging for lead-acid batteries and perform floating charge for 1 hour after the green light is on; activate the BMS (Battery Management System) low-temperature protection function for lithium batteries and prohibit charging below 0°C.
- 4.Regular maintenance: For lead-acid batteries, test the electrolyte density and liquid level weekly and remove plate sulfation; for lithium batteries, check BMS data monthly to ensure normal temperature monitoring.
